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Faulhaber MCBL 3603 Series, Operating Instructions Manual

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8

Start-up procedure

PWR

MOTOR

COM1

Computer cable 
RS232 / RS485
RS485easy-Bus

*

PLC I/O (12 inputs / 8 outputs)

  1   GND

  7   Z index (if no index NC)

  3   B channel

  5   A channel

  2   Vcc logical (5 VDC)

Encoder

  1   GND

  2    Power Supply (12-50 VDC)

  3   Motor (-)

  4   Motor (+)

DC-Micromotor

ENCODER 

OPTIO

optional digital I/O

COMPUTER INPUT

*

optional adapter for

 RS 485easy-Bus

1

1

5

1

5

6

10

11

15

PLC I/O description
The PLC I/O port enables direct communication with the position control function without
having to use a computer. For example, once a program has been created, it can be
executed by simply giving a command to the assigned input. In the initial phases of
installation, and to allow the user to better understand the operation of the motion
controller, all instructions are given via computer. It is therefore not necessary to connect
this port.

RS232 description
This port is the communication link between the motion controller and the external
computer via the COM1 connection point. Additional information regarding the
connection and set-up is given in chapter 29. The link is make with a standard
computer cable which, if necessary, can be optionally supplied by Minimotor.

7. Connection diagram for MCDC 3603

Specifications subject to change without notice

Summary of Contents for MCBL 3603 Series

Page 1: ...MCDC 3603 MCBL 3603 Series Operating Instructions Brushless DC Servomotors Motion Controller 4 Quadrant PWM for DC Micromotors and Series Edition 20 02 2001 ...

Page 2: ...instruction manual on line www minimotor ch uk pr For direct Download w w w f a u l haber com Miniature Drive Systems Micro Drives DC Micromotors Precision Gearheads Servo Components Drive Electronics http www minimotor ch minicatalog pdf DriveCircuits Manuals IM_e_MCDC_MCBL_3603 pdf ...

Page 3: ... and installation 30 15 Loading an application program from the computer to the motion controller 30 16 Saving the motion controller application on disk 31 17 Verification of installed version 31 18 Installation of new up date basic program 32 19 Call up program from normal inputs 33 20 Call up program from binary coded digital inputs 34 21 Example of sequential multi axis application 35 22 Analog...

Page 4: ...a wide range of applications insertion and handling machines machine tools robots X Y tables drive and automation systems in medical technology chemical and food industry etc Programming One of the most important objectives in the development of these units was to keep its operation as simple as possible This has been attained with the use of just a few highly efficient functions Manual balancing ...

Page 5: ... RELAY EXTERNAL PLC ECT CURRENT LIMIT I Peak I Nominal VELOCITY f V f I TEMP SENSOR OVER VOLT MONITOR BALLAST CIRCUIT HA A PH A PH B PH C SERVOMOTOR BRUSHLESS Brushless DC Servomotor Encoder RS485 OPTIONAL MENUE SET UP HOME FUNCTION PROGRAM INDEX PROGRAM MOTION UP DATE PROGRAM SAVE LOAD APPLICATION SWITCHED POWER SUPPLY 5V 12V INTERNAL PLC LOGIC INPUT FUNCTION BCD CODED PROGRAM POWER DC QUADRATURE...

Page 6: ...Program memory 16 bit access Sampling period Number of programs Lines per program Number of indexes MCBL 3603 MCDC 3603 RS232 RS485 RS485easy Bus 3 LED s 12 optional 8 optional integrated ASCII terminal via serial interface via serial interface via encoder Z index via external sensor Interface Status display Optional inputs 5V pull up standard 24V pull down on request Optional outputs 6 x 50V 500m...

Page 7: ...ction Encoder 1 and Hall sensors Input for special function RS232 Optional digital Input Output 1 2 3 4 5 Connection for MCDC 3603 Power supply motor motor connection Encoder 1 Input for special function RS232 Optional digital Input Output 1 Line driver encoders for noisy environments or long distances can be used Specifications subject to change without notice 1 2 3 4 5 ...

Page 8: ...R Power the motion controller Software start up Start up Procedure for MCDC 3603 Connect the motor terminals to MOTOR Connect the encoder to ENCODER Connect the RS232 or RS485 to the computer port COM Connect the power supply to PWR Power the motion controller Software start up The computer link is necessary to program the motion controller After programming has been completed the computer link ca...

Page 9: ...ensor B 13 Hall sensor C 15 Vcc logical 5 VDC 1 GND 7 Z index if no index NC 3 B channel 5 A channel 2 Vcc logical 5 VDC Encoder 1 GND 2 Power Supply 12 50 VDC 3 Phase A 4 Phase B 5 Phase C Brushless DC Servomotor ENCODER HALL OPTIO optional digital I O COMPUTER INPUT optional adapter for RS 485easy Bus 1 1 5 1 5 6 10 11 15 Specifications subject to change without notice ...

Page 10: ...ogram has been created it can be executed by simply giving a command to the assigned input In the initial phases of installation and to allow the user to better understand the operation of the motion controller all instructions are given via computer It is therefore not necessary to connect this port RS232 description This port is the communication link between the motion controller and the extern...

Page 11: ...m xx36_yyy S19 basic motion controller software terminal emulator for Windows program MM_WIN TRM with the pre defined terminal emulator parameters To copy the software onto your hard disk using Windows first of all start the installation program from the DOS prompt which copies the contents of the diskette into a directory MIMO_MC which is automatically created You should now work only on your har...

Page 12: ...ons For additional information see chapter 26 Program xx36_yyy S19 Is the basic working program which realises all described functions and programming possibilities This program is already installed within the unit and automatically goes into operation once the system is started up Application user programs Contains the complete set of customer defined data and parameters application General instr...

Page 13: ...dual parameters to be set according to the requirements of the specific application A description on how to optimise the system is contained in chapter 11 As an initial step the user should familiarise himself with the motion controller instructions which are available via the ON LINE CONTROL menu As we will see later it is important to first get the motor running before optimising the parameters ...

Page 14: ... is smoothed out this reducing mechanical stress for better live performance MODE 0 Programs and commands operated using the standard inputs see chapter 19 2 Programs and commands operated using the standard inputs PULSE DIRECTION input signal for stepper control emulation function active see chapter 23 3 Programs and commands operated using the standard inputs Analogue input signal for digital sp...

Page 15: ...e control 10 1 Execute functions The EXECUTE FUNCTIONS menu only lists a selection of the most important available instructions However other functions can be executed via this menu Specifications subject to change without notice ...

Page 16: ...hereby if not zero jump to line xx Number index pre load for changing index parameters by remote control Run program Position absolute Proportional closed loop parameter Servo amplifier power OFF Power ON reset position counter Power ON continue keep position counter Required identifier for RS485easy Bus Repeat way CW CCW Repeat way same direction Set loop reference letter five possibilies from A ...

Page 17: ...peed profile can be programmed PW ENTER The motor is stationery and maintains its position JP ENTER The motor runs at a constant CW speed SP10000 ENTER The motor runs at 2 500 lines s EC ENTER The encoder counter value appears on the screen To return to the previous menu press ESC SM ENTER The motor stops and maintains its position PQ ENTER The power stage is switched off Specifications subject to...

Page 18: ...at 0 TACCEL ACCEL SPEED TACCEL Encoder resolution Using the two encoder channels the motion controller internal electronics multiply the encoder resolutions by 4 For example when using a 500 line incremental encoder one revolution of the motor shaft corresponds to 2 000 lines Therefore WAY 2 000 corresponds to one motor shaft revolution Acceleration and deceleration When setting the acceleration t...

Page 19: ...ng these instructions all parameters even set up can be changed on line thus enabling the user to see the reaction of the system whilst making changes One helpful function is the EC encoder counter which gives information on the actual motor shaft position Improved dynamics If your application requires more dynamics this can be obtained by increasing the PROPORTIONAL DERIVATIVE and VELOCITY LOOP v...

Page 20: ...actical examples of how the motion can be controlled are to be found at the end of this section 12 1 Home function This is the fixed reference starting home position The home command can be given when ever the system should return to the home position Specifications subject to change without notice ...

Page 21: ...t as follows DIR_H 0 SPE_H 0 INP_H 0 For an extremely precise home position use first the external position sensor and then the encoder Z index In this case all 5 lines in the home function menu must be set There is also a possibility to set the home function without using either an external sensor or the encoder Only in this case all parameters are set to zero and the system s position at the tim...

Page 22: ...he distance to be travelled must be programmed ACCEL Acceleration k lines per second2 SPEED Speed in lines per second DIST Distance in lines TYPE Absolute to the home position or relative to the actual position see chapter 13 time speed lines s speed TDECEL TACCEL 0 TACCEL ACCEL SPEED TACCEL For example to execute index 3 in the ON LINE CONTROL menu you must enter IX3 ENTER 12 2 Index ...

Page 23: ...rupt program as long as input is active LL Limit switch left LR Limit switch right HO Execute HOME according to HOME FUNCTION IX xx Execute index number xx JN xxxxxx Jog negative constant speed xxxxxx lines sec CCW as long as input active JP xxxxxx Jog positive consistent speed xxxxxx lines sec CW as long as input active SO x Set output x CO x Clear output x PG xx Execute program xx 12 3 Input fun...

Page 24: ... corresponding opposite direction is only possible For all other functions an already active function is always completed before the next one is executed If several functions are active at the same time the one with the lowest input number is executed first from top to bottom To run a program endlessly activated via a INPUT see example in INPUT 7 above simply keep the selected input active The cur...

Page 25: ...e outputs can also be similarly programmed but with different possibilities The following is a list of the instructions that can be executed directly via the OUTPUT FUNCTION menu EDPG End of program ERR Error HOME Home has been executed Output are set when status is occurring open collector to logic 0 Specifications subject to change without notice ...

Page 26: ... loop reference letter five possibilies from A to E and number of repeats xxxx 1 10 000 JNZ letter xx Indicate loop reference letter from A to E Decrements the loop repeats whereby if not zero jump to line xx This menu allows us to program up to 15 separate programs with a maximum of 50 lines each The system selects and executes the instructions line by line The system considers the program as fin...

Page 27: ...ided into four distinct phases Starting position home First displacement index 1 Waiting time WT Second displacement index 2 How to enter the program data It is important to remember that the motion controller works using the encoder line information In other words the displacement movement speed and acceleration parameters are entered in lines lines second and lines second2 respectively As alread...

Page 28: ...rpm 60 4 CPRencoder lines SPEED lines s 61 5rpm 60 4 500lines 2050lines s Equation Acceleration deceleration Therefore ACCEL lines s2 SPEED lines s TACCEL s ACCEL lines s2 2050lines s 0 122s 16803lines s2 17000lines s2 Equation The distance can also be measured using the encoder counter command EC in the execute function menu when the servo amplifier is unpowered 7 segment display at zero Specific...

Page 29: ...lacement From the last item on the INDEX menu we have the possibility of defining the two possible types of displacement relative or absolute The method for doing this is as described below Relative displacement By relative we mean that the displacement commences from the position of the motor shaft at the time that the instruction is executed Therefore to make three complete CCW rotations the mot...

Page 30: ...her words to return to the 4 000 line position the motor has to go back 6 000 lines from its actual position at 10 000 lines Waiting time The 2 second waiting time is simply defined using the WAIT TIME instruction Writing the program Now that all the phases have been defined the final instructions are entered in the PROGRAM menu in the correct sequence See input sequence above Specifications subje...

Page 31: ...nt IX2 for the second displacement Entering PG1 executes the complete program Loop There are two loop instructions SET letter and JNZ letter which permit a particular program part to be repeated for a pre defined number of times Within any one program a maximum of five loops can be defined from A to E In the following we instruct part of program PG1 IX1 WT and IX2 to be repeated five times Specifi...

Page 32: ...when executing the LAPP command If the application should be saved first use the SAPP command prior to using LAPP command see chapter 16 LAPP ENTER Ready for receiving application PLEASE TRANSMIT filename xxx User program terminated G Select the following functions from the Terminal MM_WIN TRM screen Transfers Send Text file Choose the name of the application to be loaded filename xxx and press OK...

Page 33: ...l MM_WIN TRM screen Transfers Receive Text File Name the application to be saved filename txt and press OK Then press CTRL G followed by ENTER IL S2 S2 S8 Note S8 is the last line Select STOP The application is now saved on hard disk diskette under given file name Press CR to return to the motion controller program VER ENTER The following text will appear on the screen FAULHABER GROUP MCxx Program...

Page 34: ...Select the following functions from the Terminal MM_WIN TRM screen Transfers Send Text File Select the file type option to all data and then choose the file xx36_yyy S19 and press OK G IL File MCxx_yyy Loading done When reappears start the motion controller by writing G space R followed by two line returns Alternatively turn the system off and on The new application is now loaded Loading saving ve...

Page 35: ... 19 20 21 22 23 24 13 14 15 16 PIN Function PLC I O 19 Call up program from normal inputs Optional I O The procedure to execute a program or another instruction via the 8 normal inputs is as follows assign the instruction to the desired input via the INPUT FUNCTION menu activate the input via an external circuit see example below Specifications subject to change without notice ...

Page 36: ...sed as binary coded program numbers The trigger to start the pre selected program is input line 8 Program number 0 is not used Therefore pre select program number with binary switch numbers 1 15 start program with start button S OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 COM GND GND VCC IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 IN 11 IN 12 1 2 3 4 5 6 7 8 9 10 11 12 17 18 19 20 21 22...

Page 37: ...5 16 S BCD Motion Controller 1 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 COM GND GND VCC IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 IN 11 IN 12 1 2 3 4 5 6 7 8 9 10 11 12 17 18 19 20 21 22 23 24 13 14 15 16 PIN Function Motion Controller 2 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 COM GND GND VCC IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 IN 11 IN 12 PIN Function 1 2 3 ...

Page 38: ... and CCW operation The maximum speed is defined with the SP command For high dynamics we recommend increasing the AC value AC 2 000 000 GND 5V or 10V PULSE ch B DIRECTION ch A DIRECTION ch A PULSE ch B 10V 0 10V 1 2 3 4 5 6 7 8 PIN Function OPTIO External voltage GND 10V PULSE ch B DIRECTION ch A DIRECTION ch A PULSE ch B 10V 0 10V 1 2 3 4 5 6 7 8 PIN Function OPTIO Potentiometer Specifications su...

Page 39: ... 8 PIN Function OPTIO Stepper controller CW CCW Pulse With this feature up to 32 motion controllers can be adressed and controlled by one host computer using a simple RS485 interface The connection principle is show below 24 RS485easy Bus Motion controller 1 6 7 8 9 RX RX TX TX Motion controller 2 6 7 8 9 RX RX TX TX Motion controller n 6 7 8 9 RX RX TX TX Axis manager RX RX TX TX 6 7 8 9 PC PLC o...

Page 40: ...s used as a default value for single axis application For multi axis operation a number from 1 99 should be used Number 1 must always be used see below 2 Realise an RS485 connections and set the baud rate in the terminal emulator software to 19 200 To use the RS485 it is necessary to have a RS232 RS485 converter since PCs usually only offer a RS232 interface 3 To operate a motion controller it is ...

Page 41: ...r of increments defined in DP deviation position 60 Power stage over heating 80 C detected by the temperature sensor 61 Power supply over voltage Power supply voltage or retarding energy on ballast circuit to high 62 Ballast circuit active too long If the ballast circuit is active for more than 5 seconds the power stage is switched off 26 Operating system error If the message user program corrupte...

Page 42: ... controllers are provided with an internal fuse Braking energy When decelerating the motor brake energy is developed This energy increases the motion controller voltage supply Therefore the motion controllers supplied with an internal ballast circuit which converts this energy into heat Wiring A well known disadvantage of PWM pulse width modulation is that it generates a lot of interference In ord...

Page 43: ...B High Density D SUB normal 2 3 15 8 26 9 Power supply Motor phases Encoder input encoder 1phases Hall effect sensors Pulse dir analogue encoder 2 12 inputs 8 outputs Serial interface RS232 RS485 RS485easy Bus WAGO Multiconnector 5 0mm D SUB High Density Modular RJ45 D SUB High Density D SUB normal Motor PWR Encoder Optio PLC I O optional RS 232 RS 485 RS 485easy Bus Hall 1 5 10 15 1 6 11 1 5 Moto...

Page 44: ...ult x x x OFF ON x RS232 2 400 baud x x x ON OFF x RS232 4 800 baud x x x ON ON x RS232 19 200 baud Computer 25 pol D Sub Motion Controller 9 pol D Sub Computer 9 pol D Sub Motion Controller 9 pol D Sub 2 TX 3 RX 5 GND TX 2 RX 3 GND 7 RTS 4 CTS 5 DSR 6 DCD 8 DTR 20 2 TX 3 RX 5 GND TX 3 RX 2 GND 5 RTS 7 CTS 8 DSR 6 DCD 1 DTR 4 By turning the system off and back on the new baud rate will be activate...

Page 45: ...in 15 Pin 16 Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 COMMON GND GND VCC Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 1 GND 5V Input 9 2 Input 10 2 Input 11 2 Input 12 2 1 Program start trigger with BCD coded input MODE 10 2 BCD coded input for program 1 15 selection MODE 10 Joint cathodes of output free wheeling diodes 1 6 2A 2A 5 V 250 mA Pull up...

Page 46: ...ferential input 26LS32 Pin 10 Hall A middle level pull up 2 4k to 5V pull down 2k differential input 26LS32 Pin 11 Hall B Pull up 2 4k to 5V differential input 26LS32 Pin 12 Hall B middle level pull up 2 4k to 5V pull down 2k differential input 26LS32 Pin 13 Hall C Pull up 2 4k to 5V differential input 26LS32 Pin 14 Hall C middle level pull up 2 4k to 5V pull down 2k differential input 26LS32 Pin ...

Page 47: ... on request Pin 3 Pulse pull up 2 4k to 5V differential input 26LS32 Pin 4 Direction pull up 2 4k to 5V differential input 26LS32 Pin 5 Direction middle level Pull up 2 4k to 5V pull down 2k differential input 26LS32 Pin 6 Pulse middle level Pull up 2 4k to 5V pull down 2k differential input 26LS32 Pin 7 10V analogue input reference range 10V Pin 8 0 10V analogue input reference range 0 10V ...

Page 48: ...r de www faulhaber de MINIMOTOR SA 6980 Croglio Switzerland Tel 41 0 91 611 31 00 Fax 41 0 91 611 31 10 Email info minimotor ch www minimotor ch MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 USA Phone 1 727 572 0131 Fax 1 727 573 5918 Toll Free 800 807 9166 Email info micromo com www micromo com MINIMOTOR SA Edition 20 02 2001 ...

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